Motor interconnect device

ABSTRACT

A fan assembly having a reduced dimension formed by several modifications is described. The fan assembly includes a stator having stator coils positioned within a recessed portion of a pillow that receives the motor. The stator may include wire connections positioned between adjacent stator coils and designed to terminate wires of the stator coils. The wire terminations may be on a protrusion or a post positioned between adjacent stator coils, or alternatively, the wire terminations may be disposed on protruding features of a bushing. The protrusion may be formed from an electrically conductive material and electrically connected to a motor control circuit via a flexible printed circuit. In some embodiments, the protrusion is part of an electrically neutral stator bushing having several pins. Also, a gap region between the bushing and a flange feature is designed to improve an adhesive joint.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/795,822, filed on Jul. 9, 2015, and titled “MOTOR INTERCONNECTDEVICE,” which claims the benefit of priority under 35 U.S.C. §119(e) toU.S. Provisional Application No. 62/022,600, filed on Jul. 9, 2014, andtitled “MOTOR INTERCONNECT DEVICE,” and to U.S. Provisional ApplicationNo. 62/023,732, filed on Jul. 11, 2014, and titled “MOTOR INTERCONNECTDEVICE,” the disclosures of which are incorporated herein by referencein its entirety.

FIELD

The described embodiments relate generally to a component within anelectronic device. In particular, the present embodiments relate to anelectronic device having a motor with a reduced height which may allowfor reduced dimensions of the electronic device.

BACKGROUND

Centrifugal fans are commonly used in computing systems and otherelectronic devices to provide cooling of the central processing unit(CPU), graphics processing unit (GPU) and/or other modules. Newerproduct generations typically introduce new features and/or fasterprocessors that offer improved computing performance. Additionally, inthe area of portable electronic devices, reduction in the overallthickness of the computer, particularly the enclosure, is a common goalfor improving portability and customer appeal. In order to compensatefor a smaller enclosure, a cooling fan may include a fan having areduced motor height, which can compromise the motor performance.

However, as a result of these upgrades, higher thermal loading may beimposed on the system, which consequently requires increased airflowfrom the cooling fan to avoid overheating or throttling of processorperformance to stay within sustainable temperature ranges. Also, asenclosures of portable electronic devices continue to have reduceddimensions, airflow through enclosures becomes highly impeded, resultingin increased demands on the cooling fan while at the same time requiringthat the fan conform to the dimensions of the enclosure. Unfortunately,a cooling fan with a motor of reduced height corresponds to a fan havingless torque delivery. Also, simply reducing the size of traditionalcooling fans compromises the space needed to accommodate an electricalconnection means for the fan motor.

Further, as enclosures of the computing systems become thinner, thespace allocated for the motor and bearing is reduced, resulting in lessspace for mechanical attachment means. Any compromise on the impellerattachment to the pillow or base of the fan can result in reduced shockrobustness, which is also a critical requirement of portable computingsystems.

SUMMARY

In one aspect, a fan assembly is described. The fan assembly may includea bushing that includes a channel. The fan assembly may further includea pillow having a flange feature extending into the channel. In someembodiments, the flange feature includes a first axial surface separatedfrom a first surface of the channel by a first gap distance and a secondaxial surface separated from a second surface of the channel by a secondgap distance different from the first gap distance. Also, the secondsurface may be different from the first surface.

In another aspect, a fan assembly having a longitudinal axis thatextends through a center of the fan assembly is described. The fanassembly may include a pillow comprising a pillow interface surface. Thefan assembly may further include a bushing that extendscircumferentially around the longitudinal axis and having a bushinginterface surface that cooperates with the pillow interface surfacedefining an interface channel comprising an axial channel component thatis parallel to the longitudinal axis. In some embodiments, the interfacechannel includes an axial channel component having a width, orthickness, that varies in accordance with a radial distance from thelongitudinal axis.

In another aspect, a fan assembly suitable for use in a portablecomputing system is described. The fan assembly may include a pillowincluding a flange portion. The fan assembly may further include a coversecured with the pillow. The cover may include a channel that receivesthe flange portion. The fan assembly may further include an adhesivedisposed in the channel to adhesively secure the cover with the pillow.In some embodiments, the adhesive includes a graduated thickness.

In another aspect, a fan assembly suitable for use in a portablecomputing system is described. The fan assembly may include a first partincluding a flange portion. The fan assembly may further include asecond part secured with the first part. The second part may include achannel that receives the flange portion. The fan assembly may furtherinclude a first clearance formed by a gap between an inner surface tothe flange portion and the surface facing the channel and a secondclearance formed by the gap between the outer surface of the flangeportion and another facing surface of the channel. The first clearanceand the second clearance may run parallel to each other. The fanassembly may further an adhesive disposed in both the first clearanceand the second clearance and disposed to adhesively secure the secondpart with the first part.

Other systems, methods, features and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the embodiments, and be protected by the followingclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, wherein likereference numerals designate like structural elements, and in which:

FIG. 1 illustrates an isometric view of a fan assembly;

FIG. 2 illustrates a partial cross sectional view of the fan assembly inFIG. 1, taken along line 2-2;

FIG. 3 illustrates an isometric view of an embodiment of an electronicdevice in an open configuration;

FIG. 4 illustrates an isometric view of a fan assembly in accordancewith the described embodiments;

FIG. 5 illustrates a plan view of an internal portion of a top case ofan electronic device having a fan assembly positioned within theinternal portion, in accordance with the described embodiments;

FIG. 6 illustrates a partial cross sectional view of a fan assemblyshown in FIG. 4 taken along line 6-6, in accordance with the describedembodiments;

FIG. 7 illustrates an isometric top view of the bushing, in accordancewith the described embodiments;

FIG. 8 illustrates an isometric bottom view of the bushing shown in FIG.7;

FIG. 9 illustrates a cross sectional view between the bushing (shown inFIGS. 7 and 8) and a pillow;

FIG. 10 illustrates an isometric view of an embodiment of a pillowdesigned to receive a fan assembly;

FIG. 11 illustrates a plan view of an alternate embodiment of a fanassembly, in accordance with the described embodiments;

FIG. 12 illustrates a partial isometric view of the fan assembly show inFIG. 11 showing additional features of the pillow and the cover;

FIG. 13 illustrates a cross sectional view of the fan assembly shown inFIGS. 11 and 12, further showing the pillow adhesively secured with thecover;

FIG. 14 illustrates an isometric view of an embodiment of a statorhaving coils with wires electrically connected with protrusions attachedto a flexible printed circuit assembly;

FIG. 15 illustrates an isometric view of an embodiment of a printedcircuit assembly having posts as well as an elongated portion designedto electrically connect with another component;

FIG. 16 illustrates an isometric view of an embodiment of a statorsurrounding a bushing, in accordance with the described embodiments;

FIG. 17 illustrates a top view of an embodiment of a stator bushinghaving connections points for wire termination;

FIG. 18 illustrates a bottom view of the stator bushing shown in FIG.17, in accordance with the described embodiments;

FIG. 19 illustrates an isometric view of a stator and stator bushingassembled with a pillow of an electronic device, in accordance with thedescribed embodiments; and

FIG. 20 illustrates a flowchart showing a method for reducing adimension of a motor.

Those skilled in the art will appreciate and understand that, accordingto common practice, various features of the drawings discussed below arenot necessarily drawn to scale, and that dimensions of various featuresand elements of the drawings may be expanded or reduced to more clearlyillustrate the embodiments of the present invention described herein.

DETAILED DESCRIPTION

Reference will now be made in detail to representative embodimentsillustrated in the accompanying drawings. It should be understood thatthe following descriptions are not intended to limit the embodiments toone preferred embodiment. To the contrary, it is intended to coveralternatives, modifications, and equivalents as can be included withinthe spirit and scope of the described embodiments as defined by theappended claims.

In the following detailed description, references are made to theaccompanying drawings, which form a part of the description and in whichare shown, by way of illustration, specific embodiments in accordancewith the described embodiments. Although these embodiments are describedin sufficient detail to enable one skilled in the art to practice thedescribed embodiments, it is understood that these examples are notlimiting such that other embodiments may be used, and changes may bemade without departing from the spirit and scope of the describedembodiments.

FIG. 1 illustrates an isometric view of a fan assembly 100 that may bedisposed within an electronic device, such as a laptop computing device.The fan assembly 100 can include a cover 102 that conceals a portion ofan impeller 104. FIG. 2 illustrates a partial cross sectional view ofthe fan assembly 100 shown in FIG. 1, taken along the line 2-2. Asshown, the fan assembly 100 includes various structural components,which may limit the ability to reduce its overall size, and in turn,limits the ability to reduce a size or dimension of an electronic devicethat includes the fan assembly 100. For example, the motor hub 108 andthe printed circuit 124 are separated by a clearance region defined by adistance 130 shown in a z-direction. The distance 130 is due in part tothe dimension of a first stator coil 118 and a second stator coil 120,both of which are attached to a stator 114. Also, each of the statorcoils includes a wire portion that terminates in a location between themotor hub 108 (along with a portion of a magnet 122) and the printedcircuit 124. For example, the wire portion 126 of the first stator coil118 is terminated, via solder 128, between the motor hub 108 and theprinted circuit 124. The presence of the solder 128 between the motorhub 108 and the printed circuit 124 may limit how close the motor hub108 and the printed circuit 124, which may affect the overall height 132of the fan assembly.

In addition, the fan assembly 100 is secured to a pillow 112 (or base).This is achieved by adhesively securing an outer surface of the bushing116 to an inner surface of a flange feature 142 of the pillow 112. Asshown in FIG. 1, 1) the bushing 116 extends circumferentially around alongitudinal axis 162 extending through the center of rotation of thefan assembly 100, and 2) the flange feature 142 extendscircumferentially around the bushing 116. In order to center an impeller(not shown) used with the fan assembly 100, the inner surface of theflange feature 142 registers against the outer surface of the bushing116. The function of centering the fan assembly 100 requires a smallradial gap and a bond line thickness of the adhesive filling this radialgap may not be optimal for maximizing the joint strength. Adhesives usedfor these types of joints typically have peak strength when the bondline is approximately 0.05-0.1 millimeters (mm) thick. For this reason,the bushing 116 includes a circumferential groove 144 (shown in theenlarged view) in which the radial gap is closer to the optimal bondline thickness for whatever adhesive is chosen. This results in an evensmaller “effective” axial length (in the direction of the longitudinalaxis 162) of the adhesive joint, resulting is greatly diminished jointstrength.

In the present disclosure, the described embodiments allow for reducinga dimension of a fan assembly while maintaining the integrity (e.g.,torque delivery) of the fan assembly. In particular, a thickness, orz-height, of the fan assembly may be reduced in order to form a morecompact form factor. Although reducing the dimension of the fan assemblyreduces space for components, the components in the present disclosureare redesigned. For example, a fan assembly may use space between coils,which is traditionally unused space, in order to electrically connectcoil lead wires to another component. Traditional connection of leadwires of a stator coil may be performed below a component (e.g., magnet)of the fan assembly using an operation such as soldering. However, inthe present disclosure the lead wires are connected in differentlocations such that a motor hub may be repositioned, i.e., lowered, to alocation previously occupied by traditional connection means of the leadwires. Also, because the connection is performed in the previouslyunused space, little, if any, modification or retrofitting of othercomponents is required.

Also, in some embodiments, a pillow (or substrate) positioned below thefan assembly may include one or more recessed portions that receives thestator coils. In some embodiments, the pillow is formed from aninjection molding operation in which the recessed portions are formedduring formation of the pillow. In other embodiments, the recessedportions formed subsequent to formation of the pillow. In this manner,the recessed portions may be formed by a material removal operation. Ineither event, the recessed portions of the pillow may define an annular(or ring) shape. Alternatively, the recessed portions may define severalindividual recessed portions of the pillow, with the number of recessedportions corresponding to the number of stator coils. Also, the recessedportions may include a size and a shape to receive a portion of thestator coils.

Further, the present disclosure describes adhesive joints which maycompensate for fan motor assemblies having a reduced size which in turnincludes reduced surface area to form the adhesive joint. In thisregard, a bushing of the fan assembly may be modified to receive aflange feature of the pillow. Further, the gap region defined by a spacebetween the bushing and the flange region may include varying gapdistances. For example, the gap region may include a first gap distanceand a second gap distance greater than the first gap distance. In thismanner, the strength of the adhesive joint formed in the gap region maybe substantially increased, and the fan assembly is more resistant toload bearing events even in instances when the electronic device (thatincludes the fan assembly) includes a reduced size.

These and other embodiments discussed below with reference to FIGS. 3-19illustrate a motor having a reduced dimension but without reducedperformance (e.g., reduced torque delivery). However, those skilled inthe art will readily appreciate that the detailed description givenherein with respect to these Figures is for explanatory purposes onlyand should not be construed as limiting.

FIG. 3 illustrates an isometric view of an electronic device 200 in anopen configuration. In some embodiments, the electronic device 200 is aportable electronic device such as a MACBOOK PRO®, made by Apple, Inc.,from Cupertino, Calif. In other embodiments, the electronic device 200is a different consumer electronic device designed to offer and/ordisplay various visual content. As shown, the electronic device 200includes a lid portion 202 pivotally connected to a base portion 204,both of which may be formed from a metal, such as aluminum or aluminumalloy. As shown, the lid portion 202 includes a display 206 designed todisplay visual content such as a graphical user interface, still imagessuch as photos, as well as video media items such as movies. The display206 may be electrically connected with one or more processors (notshown) in the base portion 204.

The base portion 204 may include a top case 208. As illustrated in FIG.3, the top case 208 is designed to accommodate various user inputdevices such as a keyboard 212 and a touchpad 214. In particular, theseuser input devices may be exposed such that a user may interact with theinput devices when the electronic device 200 is positioned in the openconfiguration. Further, the base portion 204 may include a bottom case(not shown). The bottom case along with top case 208 may cooperate toreceive various other electronic and mechanical components.

Although not shown, the electronic device 200 may include severalelectronic components such as a mass storage device (e.g., a hard driveor a solid state storage device such as a flash memory device includingnon-transitory and tangible memory that may be, for example, volatileand/or non-volatile memory) configured to store information, data,files, applications, instructions or the like, a processor (e.g., amicroprocessor or controller) configured to control the overalloperation of the portable electronic device, a communication interfaceconfigured for transmitting and receiving data through, for example, awired or wireless network such as a local area network (LAN), ametropolitan area network (MAN), and/or a wide area network (WAN), forexample, the Internet, a fan, a heat pipe, and one or more batteries.

FIG. 4 illustrates an isometric view of a fan assembly 300 in accordancewith the described embodiments. In some embodiments, the fan assembly300 is a centrifugal fan designed to cool several components within anelectronic device (such as the electronic device 200 shown in FIG. 3).The fan assembly 300 may include a cover 302 that covers a portion ofthe impeller 304. The cover 302 may include an opening 306 defining aninlet region for air to flow through the impeller 304. The fan assembly300 may further include a motor hub 308, a bearing 310, and a motor (notshown) below the motor hub 308. In some embodiments, the motor is a3-phase brushless DC motor.

The fan assembly 300 may further include a pillow 312 designed toreceive and hold one or more components of the fan assembly 300. In someembodiments, the fan assembly 300 is positioned within a portion of anelectronic device such that the pillow 312 is positioned against aninterior portion of a top case (such as the top case 208 shown in FIG.3) to form an integrated system. In some embodiments, the impeller 304is designed to drive air received from the opening 306 toheat-dissipating components in order to cool those components. In otherembodiments, the impeller 304 receives heated air from theheat-generating components within an electronic device via the opening306, and drive the heated air along the pillow 312 and/or in a directiontoward the outlet region 315 thereby allowing the heated air to escapethe electronic device.

Also, in some embodiments, the fan assembly 300 includes a motor controlcircuit 319 electrically connected with the motor. The motor controlcircuit 319 may be configured to drive (or commutate) electrical currentthrough the stator coils (not shown) of the motor in order to generatetorque used to drive the impeller 304. In some embodiments, the motorcontrol circuit 319 is positioned within the cover 302 or the motor hub308. In the embodiment shown in FIG. 4, the motor control circuit 319 isexternal with respect to several components of the fan assembly 300,such as the cover 302, the impeller 304, and the motor hub 308. Also,the motor control circuit 319 may also be external with respect to thepillow 312. Also, in some embodiments, the motor control circuit 319 iselectrically connected with an input/output (I/O) board (not shown),which may include a main logic board (MLB). In this manner, when themotor control circuit 319 is external to other components of the fanassembly 300, the fan assembly 300 may include a lower profile (e.g.,less thickness in at least one dimension) without reduced performance.This will be discussed below. Also, although not shown, the motorcontrol circuit 319 may be electrically connected with a flexibleprinted circuit, which may be at least partially within the cover 302.

FIG. 5 illustrates a plan view of an internal portion 220 of the topcase 208 (shown in FIG. 3) having a fan assembly 300 (shown in FIG. 4)positioned within the internal portion 220. In this configuration, thepillow 312 is positioned proximate to a keyboard region 222 of the topcase 208. However, it should be appreciated that the fan assembly 300may be positioned at any suitable location within an electronic device.Also, the pillow 312 and the outlet region 315 may be positionedproximate to openings 228 of top case 208 in order to facilitate theremoval of air (such as heated air) from the electronic device.

In addition to locating the motor control circuit 319 externally withrespect to the fan assembly 300, other additional configurations maycontribute to the fan assembly having a lower profile. For example, FIG.6 illustrates a partial cross sectional view of a fan assembly 300 takenalong the 6-6 line in FIG. 4, in accordance with the describedembodiments. In this embodiment, the fan assembly 300 may include aheight 332 in the z-direction less than a height of fan motor assembliespreviously discussed (such as a height 132 of the fan assembly 100) todefine a lower profile of the fan assembly 300. This may be due in partto the fan assembly 300 including features that may facilitate reductionin the overall height of the fan assembly. For example, the fan assembly300 may include a stator 314 positioned around a bushing 316. In someembodiments, the stator 314 is formed from several silicon steel sheetslaminated together. The stator 314 may include several stator coils,such as first stator coil 318 and second stator coil 320, positioned onseveral stator poles of the stator 314. For example, the stator in FIG.6 includes a first stator coil 318 and a second stator coil 320, each ofwhich include electrically conducting coils wound around a first statorpole 338 and a second stator pole 340, respectively. For purposes ofclarity, the wire portions interconnecting the stator coils are notshown. The first stator coil 318 and the second stator coil 320 aredesigned to receive electrical current from a power source (such as abattery disposed within an electronic device) to form an electromagnet.

The fan assembly 300 further includes a magnet 322 surrounding thestator coils. The magnet 322 is a multi-polarity magnet that includes afirst polarity and a second polarity opposite the first polarity. Thefirst polarity and the second polarity may be associated with a “North”facing polarity and a “South” facing polarity, respectively, alsoreferred to as a “north” pole and “south” pole of a magnet. Although notshown, the magnet 322 may include several pairs that include a“north-south” configuration. For example, the magnet 322 may include afour-pole design having two north facing poles and two south facingpoles. Generally, the magnet 322 may include any even number of poles inwhich a north pole is paired with a south pole. Also, the magnet 322 maybe positioned around an inner circumference of the motor hub 308, asshown in FIG. 6. When electrical current passes through the statorcoils, the magnet 322, the motor hub 308, and an impeller (not shown)coupled with the motor hub 308 may be actuated, or rotated, in order todrive air in a manner previously described. Also, traditional motors mayinclude a wire connection (not shown) using solder to connect the wiresof the coils in a location, for example, directly between a magnet(and/or a motor hub) and a circuit, as shown in FIG. 2. Accordingly,this location is occupied by both a wire as well as solder, both ofwhich reduce the ability to minimize the height of a fan assembly.However, by locating this connection elsewhere within the fan assembly300 (which will be discussed below), a distance 330 (or clearance)between the motor hub and a printed circuit assembly 328 is reduced andin turn a height 332 of the fan assembly 300 is also reduced, as shownin FIG. 6. It will be appreciated that in some embodiments, the printedcircuit assembly 328 is a flexible printed circuit. However, the printedcircuit assembly 328 may be a flexible material generally known in theart for electrically connecting two or more components.

Further, the pillow 312 includes a region of removed material to defineone or more recessed portions, such as a first recessed portion 324 anda second recessed portion 326. The recessed portions are designed to atleast partially receive the stator coils. For example, as shown, firstrecessed portion 324 and a second recessed portion 326 receive the firststator coil 318 and second stator coil 320, respectively. A firstenlarged view 376 shows part of first recessed portion 324. In someembodiments, the recessed portions include a series of openingsconfigured to receive the stator coils. The holes may be referred to asblind holes, or counter bores. The number of recessed portions generallycorresponds to the number of stator coils on the stator 314. However, inother embodiments, one or more recessed portions may be designed to atleast partially receive two or more stator coils.

In addition to or as an alternative to the recessed portions of thepillow 312, the fan assembly 300 may include additional features toachieve an overall lower profile. For example, fan motor assembliesinclude stator coils electrically connected to a printed circuit via asolder/wire connection located directly between a printed circuit and amagnet, or directly between a printed circuit and a motor hub. In theembodiment shown in FIG. 6, an electrical connection (not shown) betweena stator coil and the printed circuit assembly 328 is in a locationother than a location between the magnet 322 and the printed circuitassembly 328. In this manner, the motor hub 308 and the magnet 322 maybe positioned closer to the printed circuit assembly 328 contributing tothe distance 330 (or clearance) decreasing to a distance less than thatof traditional fan assemblies.

Additional modifications may be made to the fan assembly 300 to reducethe overall height in the z-direction. For example, the motor hub 308may include an outer peripheral portion 336 shown as imaginary linesrepresenting a reduced height of motor hub 308 (in the z-direction).Despite the reduced height, it may be desirable to form the motor hub308 reducing its material thickness. For example, a thickness 337 of themotor hub 308 may not be reduced when reducing the height 332 of the fanassembly 300. This is possible due in part by positioning the statorcoils within the recessed portions (previously described) of the pillow312, thereby allowing the motor hub 308 to occupy space previouslyoccupied by the stator coils. The combination of the recessed portions,the location of the motor control circuit, and the position of the motorhub 308 in areas previously occupied by the stator coils, the distance330 between the motor hub 308 and the printed circuit assembly 328 isminimized and the fan assembly 300 includes a height 332 in thez-direction that is lower than traditional fan motor assemblies.

Also, the fan assembly 300 may be adhesively secured with the pillow312. This may be achieved by adhesively securing the bushing 316 with afirst flange feature 342 and optionally a second flange feature 344 ofthe pillow 312. It should be understood that 1) the bushing 316 extendscircumferentially around a longitudinal axis 362 extending through thecenter of the fan assembly 300, and 2) the first flange feature 342extends circumferentially around the bushing 316. The second flangefeature 344, when used, may be designed to receive (and in some cases,align) the stator coils, and may only extend around portions of thebushing 316. However, in other embodiments when the second flangefeature 344 is not used, the pillow extends in a generally flat mannerto the first flange feature 342. Further, the longitudinal axis 362 maybe referred to as an axial direction to explain and described one ormore axial interfaces, surfaces or regions. The bushing 316 may bedesigned to increase an axial interface region between the bushing 316and the first flange feature 342 such that an axial length of anadhesive joint between the bushing 316 and the first flange feature 342increases. For example, the second enlarged view 378 shows multipleaxial interface regions between a channel 346 of the bushing 316 andsurfaces of the first flange feature 342. As shown, the channel 346generally surrounds the first flange feature 342 with the dimensions andtolerances of the channel 346 designed to improve alignment duringassembly of the bushing 316. Traditional assembly may allow adhesivebetween only a single axial surface of the first flange feature 342 andthe bushing 316, and may allow for limited adhesive bonding strength.However with the channel 346 defining a gap between two axial surfacesof the first flange feature 342, the channel 346 not only improvesalignment between the bushing 316 and the pillow 312, but also allows anadhesive to flow around both axial surfaces of the first flange feature342. In this manner, multiple adhesive interfaces are formed and theadhesive may form a stronger adhesive joint. Further, the channel 346 isdesigned as part of a radial gap (between the bushing 316 and thefeatures of the pillow 312) to include a certain gap distance betweenthe pillow 312 and the bushing 316 to ensure flow of an adhesive (notshown) between the two structures. Also, the bushing 316 includes ashoulder region 368 proximate to the second flange feature 344 with theradial gap extending between the shoulder region 368 and the secondflange feature 344. This may allow for additional flow of the adhesiveto increase an adhesive bond strength. This will be discussed in furtherdetail below.

FIGS. 7 and 8 illustrate isometric view of a bushing 416 in an isolatedview, in accordance with the described embodiments. The bushing 416shown and described may include any feature or features previouslydescribed for a bushing. FIG. 7 illustrates an isometric top view of thebushing 416. As shown, the bushing 416 includes an outer surface 422designed to engage and align a stator (such as the stator 314, shown inFIG. 6). Also, an interior region of the bushing 316 further includes abore region 424 defined by a space or void of any material. The boreregion 424 is designed to receive a component of a fan assembly, such asa bearing. The bushing 416 also includes a shoulder portion 426 that maybe designed to mate with a portion of a pillow (such as the first flangefeature 342, shown in FIG. 6). For instance, the shoulder portion 426may include a size and a shape to allow an adhesive to flow between theshoulder portion 426 and a flange feature of the pillow (such as thesecond flange feature 344 shown in FIG. 6) in order to form an adhesivejoint. Further, the adhesive joint may include a thickness based uponthe dimensions of the flange feature and/or shoulder portion 426 toensure a bond line thickness of a chosen adhesive that allow theadhesive joint to include sufficient bonding strength.

FIG. 8 illustrates an isometric bottom view of the bushing 416. Thebushing 416 includes a channel 428 designed to receive a flange feature(such as the first flange feature 342 shown in FIG. 6) as well as anadhesive. The channel 428 is further designed to define a part of a gapregion to receive an adhesive in order to form an adhesive joint betweenthe bushing 416 and another structural feature. The channel 428 may beformed by a material removal process that includes, for example, alathe. However, the channel 428 may be formed during the formation ofthe bushing 416. For example, the channel 428 may be formed by injectionmolding, die casting, metal injection molding (MIM), all of which mayinclude a mold cavity that include a shape designed to form the channel428.

The relationship between a bushing and a pillow may be formed tooptimize an adhesive joint designed to bond the bushing with the pillow.In particular, a radial gap extending between multiple interface regionsof the bushing and features of the pillow may vary. For example, oneportion of the radial gap may extend between a first bushing surface anda first pillow surface (or first flange feature surface) and may includea first gap thickness defined by the separation between the firstbushing surface and the first pillow surface. Another portion of theradial gap may extend between a second bushing surface and a secondpillow surface and may include a second gap thickness defined by theseparation between the second bushing surface and the second pillowsurface. The second gap thickness may be different (for example, greaterthan or less than) the first gap thickness. Also, the radial gap mayinclude several axial channel components (defined as interface regionsin the axial direction between the bushing and the pillow) as well asradial channel components (defined as interface regions in the radialdirection between the bushing and the pillow, and generallyperpendicular to the axial channel components).

To further describe the relationship, the gap distance betweenbushing-pillow surfaces may vary based upon a radial distance from acenter of the bushing. Referring to the example above, the secondbushing surface and the second pillow surface may be positioned furtherfrom the center of the bushing than the first bushing surface and thefirst pillow surface. In some embodiments, the gap distance varies inthat the first gap distance is greater than the second gap distance.

However, the gap distance varies in that the first gap distance is lessthan the second gap distance. For example, FIG. 9 illustrates a crosssectional view between the bushing 416 (shown in FIGS. 7 and 8) and apillow 412. The pillow 412 may include several features previouslydescribed for a pillow. For example, as shown, the pillow 412 includes afirst flange feature 442 and an optionally, may further include a floorfeature 444. The enlarged view illustrates an adhesive 434 extendingbetween the bushing 416 and the pillow 412. As shown, the adhesive 434is in the channel 428 of the bushing extends around multiple axialsurfaces of the first flange feature 442, with an “axial surface”defined by an axial direction denoted by the arrow 466. With theadhesive 434 surrounding the first flange feature 442 in a manner shownin FIG. 9, an adhesive joint formed by the adhesive 434 increases thebonding strength between the bushing 416 and the pillow 412.

Also, as shown in FIG. 9, the adhesive 434 extends along additionalinterface regions. For example, the adhesive 434 may extend to alocation between the floor feature 444 and the shoulder portion 426 ofthe bushing 416. In this manner, the adhesive joint formed by theadhesive 434 secures additional features to increase the bond betweenthe bushing 416 and the pillow 412. Accordingly, when the floor feature444 is included, the floor feature 444 may act in a manner similar to anadditional flange feature and define an additional axial connect pointfor an adhesive interface. Also, while a cross sectional view is shown,it should be understood that the flange features and the adhesive 434extend in a generally circular or circumferential manner.

In addition to the adhesive 434 extending to multiple features, theadhesive 434 may vary in thickness according to the gap distancesbetween the bushing-pillow surface interfaces. In particular, thevariations in thickness may increase in a radially outward direction(denoted by an arrow 468) from a center of the bushing 416 to anexterior region of the bushing 416. For example, as shown in FIG. 9, theadhesive 434 includes a first thickness defined by a first gap distance448 between the first flange feature 442 and the bushing 416. Inparticular, the first gap distance 448 may be a distance between a firstsurface of the channel 428 and a first surface of the first flangefeature 442. The first gap distance 448 may be referred to as a distancebetween the bushing 416 and a first axial surface of the first flangefeature 442 to define a first axial channel, with the axial directiondefined by the arrow 466. Further, the adhesive 434 includes a secondthickness defined by a second gap distance 450 between a second surfaceof the channel 428 and a second surface of the first flange feature 442,with the second gap distance 450 being greater than the first gapdistance 448. The second gap distance 450 may be referred to as adistance between the bushing 416 and a first radial surface of the firstflange feature 442 to define a first radial channel. Further, theadhesive 434 includes a third thickness defined by a third gap distance452 between a third surface of the channel 428 and a third surface ofthe first flange feature 442, with the third gap distance 452 beinggreater than the second gap distance 450. The third gap distance 452 maybe referred to as a distance between the bushing 416 and a second axialsurface of the first flange feature 442 to define a second axialchannel, with the axial direction defined by the arrow 466. Accordingly,a radial gap between the first flange feature 442 of the pillow and achannel 428 of the bushing 416 includes a graduated radial gap, that is,a gap that increases in a direction. As shown in FIG. 9, the directionis a radially outward direction. In addition to creating an alignmentmeans between the bushing 416 with the pillow 412, the channel 428allows the adhesive joint formed by the adhesive 434 to increase aroundmultiple surfaces of the first flange feature 442, including multipleaxial surfaces.

The adhesive joint formed by the adhesive 434 may extend and continue toincrease in thickness in a radially outward direction. For example, asshown in FIG. 9, the adhesive 434 includes a fourth thickness defined bya fourth gap distance 454 between the bushing 416 and the pillow 412,with the fourth gap distance 454 being greater than the third gapdistance 452. The fourth gap distance 454 may also be referred to as agap between the shoulder portion 426 of the bushing 416 and a surface ofa channel region 446 defined by the first flange feature 442 and thefloor feature 444. The fourth gap distance 454 may be referred to as adistance between the bushing 416 and the channel region 446 between thefirst flange feature 442 and the floor feature 444, and defining asecond radial channel. Accordingly, a radial gap between the bushing 416and the pillow 412 may be graduated, or increased, in a radially outwarddirection from the first flange feature 442 to the floor feature 444.Also, when the radial gap is includes a desired graduated configuration(for example, as shown in FIG. 9), the circumferential groove 460 in thebushing 416 may be removed. In addition to the benefits of alignmentbetween parts and additional adhesive interfaces, the graduated radialgap may provide additional benefits. For example, the adhesive 434, whendisposed between the bushing 416 and the pillow 412, may undergo certainforces (such as capillary forces) that extract or purge air bubbles fromthe adhesive 434. In this manner, the adhesive density of the adhesive434 increases and a stronger adhesive joint may be achieved.

While the embodiment shown in FIG. 9 described a bushing-pillow surfaceinterface in which the gap distance increases in a radially outwarddirection, other embodiments may include different gap distancerelationships. For example, in some embodiments, the gap distancesdecrease in the radially outward direction. Accordingly, in otherembodiments, the first gap distance 448 shown in FIG. 9 is greater thanthe second gap distance 450, and the second gap distance 450 is greaterthan the third gap distance 452, and so on. Further, in someembodiments, a gap distance varies along a bushing-pillow surfaceinterface. As an example, in some embodiments, the first gap distance448 varies along an axial direction. In this manner, the first gapdistance 448 may increase or decrease along the axial direction. Thisdescribed variance may be representative of a variance along remainingbushing-pillow surface interfaces.

FIG. 10 illustrates an isometric view of the pillow 512, in accordancewith the described embodiments, showing various features of the pillow512. As shown, the pillow 512 includes an opening 506 and a flangefeature 542. When the pillow 512 is formed from sheet metal, the flangefeature 542 may be formed by, for example, a progressive die stampingoperation. However, another metal bending operation may be performed toform the flange feature 542, such as deep drawing, MIM, die casting,machining (including a material removal process), or the like. Also,although not shown, the pillow 512 may include a second flange featureproximate to the flange feature 542. Also, while a discrete number ofrecessed portions, such as the first recessed portion 524 and the secondrecessed portion 526, are shown, the pillow 512 may include fewer oradditional recessed portion based in part on the number of stator coils.

The exterior features of a fan assembly may include additionalenhancements. In particular, a pillow and a cover of a fan assembly mayinclude certain mating features designed to improve assembly. Forexample, FIG. 11 illustrates a plan view of an alternate embodiment of afan assembly 600, in accordance with the described embodiments. Asshown, the fan assembly 600 includes a pillow 612 and a cover 602disposed over the pillow 612. In embodiments when the cover 602 ismetal, the cover 602 may be formed from any means previously describedfor a pillow. However, in other embodiments, the cover 602 is formedfrom a polymeric material, such as plastic. Also, the pillow 612 mayinclude a flange feature 614 extending from the pillow 612. In someembodiments, the flange feature 614 is integrally formed with the pillow612. The flange feature 614 includes an opening 616 designed to receivea fastener or other object used to secure the pillow 612 with anadditional feature. Also, while a single flange feature is shown in FIG.11, in other embodiments, the pillow 612 includes two or more flangefeatures.

FIG. 12 illustrates a partial isometric view of the fan assembly show inFIG. 11 showing additional features of the pillow 612 and the cover 602.The cover 602 is separated from the pillow 612 to illustrate variousfeatures. For example, the cover 602 may include a channel 604 designedto receive a flange portion 618 of the pillow 612. The cover 602 mayfurther include a chamfered region 606 designed to accommodate thecurved profile of the flange portion 618 as shown in FIG. 12. Region 606may also be a radius or other shape instead of the chamfer shape shown.Although only a partial view is shown, it should be understood that thechannel 604 and the chamfered region 606 may extend along an outerperimeter of the cover 602 in manner similar to what is shown in FIG.12. Also, the cover 602 may further include a second channel 608designed to receive the flange feature 614. Also, the cover 602 mayinclude additional channels similar to the second channel 608 toaccommodate any additional flange features of the pillow 612.

When the flange portion 618 is positioned in the channel 604, anadhesive may flow in a remaining void or space in the channel 604.Further, the void or space may include optimal dimensions to enhance anadhesive joint formed by the adhesive. For example, FIG. 13 illustratesa cross sectional view of the fan assembly 600 shown in FIGS. 11 and 12,further showing the pillow 612 adhesively secured with the cover 602. Asshown, an adhesive 620 is disposed in the channel 604 of the cover 602and extends around the flange portion 618 of the pillow 612. Theadhesive joint formed by the adhesive 620 may exhibit several similarproperties previously described for an adhesive joint used to adhesivelysecure a bushing with a pillow. For example, as shown in FIG. 13, theadhesive 620 extends along multiple axial surfaces of the flange portion618, with an axial direction denoted by an arrow 630. Further, theadhesive 620 may include a first thickness defined by a first gapthickness 622 between a first axial surface of the flange portion 618and a first surface of the channel 604. The first gap thickness 622 maybe a smaller thickness to assist in aligning the cover 602 with thepillow. Further, the adhesive 620 may include a second thickness definedby a second gap thickness 624 between a radial surface of the flangeportion 618 and a second surface of the channel 604, with the second gapthickness 624 being less than the first gap thickness 622. Also, theadhesive 620 may include a third thickness defined by a third gapthickness 626 between a second axial surface of the flange portion 618and a second surface of the channel 604, with the third gap thickness626 being less than the second gap thickness 624. Accordingly, theadhesive 620, based upon the gap thicknesses, includes a thickness(between surfaces) that may continually increases in a direction.Further, the second gap thickness 624 may be adjusted in accordance withthe selected adhesive to ensure sufficient bond strength. Accordingly,the adhesive 620 may include a graduated, or increasing thickness. WhileFIG. 13 illustrates a side view, it should be understood that thevarious features of the pillow 612, such as the flange portion 618,extend around the pillow 612 in location other than a flange feature(similar to the flange feature 614, shown in FIG. 12). Also, the channel604 may extend around the cover 602 in location corresponding to theflange portion 618. Also, although not shown, the gap thicknesses mayincrease in the opposite direction such that the first gap thickness 622is less than the second gap thickness 624, which in turn, is less thanthe third gap thickness 626. Accordingly, in this described embodiment,the adhesive 620, based upon the gap thicknesses, includes a thicknessthat may continually increases in the opposite direction as that shownin FIG. 13.

Also, the gap thicknesses may include a size and a shape to create adesired effect with the adhesive 620. For example, the space or voiddefined by the third gap distance 626, coupled with the space or voidbetween the channel 604 and curved region 628 of the flange portion 618(or curved region 628 of the pillow 612), may combine to control anadhesive meniscus position to provide cosmetic consistency to the fanassembly 600. As shown in FIG. 13, the fan assembly 600 may include afirst clearance 632 defined in part by a first divergence rate betweenthe first axial surface of the channel 604 (which may include thechamfered region 606) and an inner surface of the curved region 628 ofthe pillow 612. The first clearance 632 may control certain dimensions(such as a size and a shape) of a first meniscus 642 formed form theadhesive 620 during a liquid (pre-cured) state of the adhesive 620during assembly. In addition, the fan assembly 600 may include a secondclearance 634 defined in part by a second divergence between the secondaxial surface of the channel 604 and an inner outer the curved region628 of the pillow 612. The second clearance 634 may control certaindimensions (such as a size and a shape) of a second meniscus 644 formedform the adhesive 620 during a liquid (pre-cured) state of the adhesive620 during assembly. In some embodiments, the first clearance 632 (and,in turn, the first divergence rate) is similar to the second clearance634 (and, in turn, the second divergence rate). In other embodiments,the first clearance 632 is different than the second clearance 634. Ineither event, both the first divergence rate and the second divergencerate can be adjusted by adjusting the first clearance 632 and the secondclearance 634, respectively. Adjusting manufacturing parameters of thepillow 612 and/or the cover 602 can in turn adjust the first divergenceand the second divergence. By adjusting the first divergence, the firstmeniscus 642 may be raised or lowered to a desired height in, forexample, a z-dimension. Also, by adjusting the second divergence, thesecond meniscus 644 may be raised or lowered to a desired height in, forexample, a z-dimension. Accordingly, by adjusting the menisci, theheight of the adhesive 620 in the z-dimension can be controlled to adesired height.

FIG. 14 illustrates an isometric view of an embodiment of a fan assembly700 that includes a stator 714 disposed on a pillow 712. The motor hubis removed for purposes of illustration. The stator 714 may includeseveral stator poles, each of which including stator coils havingelectrically conductive wires wound about the stator poles. For example,a first stator coil 718 and a second stator coil 720 (adjacent to thefirst stator coil 718) include electrically conductive wires woundaround a first stator pole 738 and a second stator pole 740 (adjacent tothe first stator pole 738), respectively. For purposes of clarity, thewire portions interconnecting the stator coils are not shown. Also, thepillow 712 includes an opening 706 allowing a printed circuit assembly728 to pass through pillow 712 and electrically connect to anothercomponent (for example, a motor control circuit 319, in FIG. 4). In someembodiments, the printed circuit assembly 728 is a printed circuitboard. In the embodiment shown in FIG. 14, the printed circuit assembly728 is a flexible printed circuit assembly.

One solution to positioning a terminating wire in a location other thanbetween a magnet and a printed circuit assembly is to form several postson the printed circuit assembly. For example, FIG. 14 furtherillustrates the printed circuit assembly 728 having several postsconnected (electrically and mechanically) with the printed circuitassembly 728. The posts may be positioned between at least some ofstator coils. For example, a first post 742 (representative of theremaining posts) is positioned between the first stator coil 718 and thesecond stator coil 720 adjacent to the first stator coil 718. As shown,the first post 742 is designed to receive a wire portion 722 from thesecond stator coil 720, with the wire portion 722 electrically connectedwith the first post 742. In this configuration, the stator coils mayinclude a wire (of a stator coil), which not only forms an electricalconnection with the printed circuit assembly 728 in a location betweenstator coils, but also in a location other than between the printedcircuit assembly 728 and a motor hub when the motor hub is installed.This allows for a clearance free of connections between the motor huband the printed circuit assembly 728 and a height of the fan assembly700 may be reduced.

Each post may also be referred to as a boss. Also, each post may bemounted onto the printed circuit assembly 728 by, for example, surfacemount technology (“SMT”). Surface mount technology may include anassembly process in which a circuit board (for example, a printedcircuit assembly 728) passes through a “pick-and-place” machine designedto assemble the posts (such as the first post 742) onto the circuitboard. Also, in some embodiments, the posts are formed from copper. Inother embodiments, the posts formed from brass. Generally, posts may beformed from any electrically conductive material (or materials) known inthe art that may electrically connect with the printed circuit assembly728. As such, the posts may facilitate electrical conduction from thewires of stator coils to the printed circuit assembly 728, or viceversa. In any case, the posts may include a metallic plating formed froma material such as tin in order to facilitate the solderability neededfor the wire connection (such as the wire portion 722) to a first end ofa post and the SMT reflow process used to attach a second end of thepost to the printed circuit board. Also, in some embodiments, the postsmay include an insulated, non-electrically conductive material on anexterior portion (e.g., curved lateral surface) in order to preventelectrical shorting to adjacent stator coils such as the first statorcoil 718 or the second stator coil 720. For example, an exterior portion746 of the first post 742 is shown in FIG. 14. Also, although not shown,each post in FIG. 14 may include a pre-applied solder material designedto facilitate an electrically connection between the wire portions andthe posts.

The connection means for connection of a wire portion on the posts mayinclude conductive adhesive, soldering or other methods for achievingelectrical connection. Also, as shown in FIG. 14, the posts may beelevated in order to facilitate the manufacturing process. For example,the first post 742 is elevated relative to the first stator coil 718 andthe second stator coil 720, allowing for tools, such as a solderingtool, to access the first post 742 without contacting the first statorcoil 718 and/or the second stator coil 720, thereby decreasing thelikelihood of damage during manufacturing and increasing the likelihoodof improved manufacturing times and throughput. Also, the posts may bepositioned between adjacent stator coils and may be centered between theadjacent stator coils. By positioning posts between at least some of thestator coils, the fan assembly 700 uses space previously unoccupied. Inthis manner, the fan assembly 700 can reduce its height in a dimension(such as a z-dimension) to reduce the overall height of the fan assembly700, and in turn, reduce an overall height of an electronic device thatincludes the fan assembly 700.

FIG. 15 illustrates an isometric view of an embodiment of a printedcircuit assembly 828 having several posts as well as an elongatedportion 830 designed to electrically connect with another component. Theprinted circuit assembly 828 may be used with a fan assembly previouslydescribed. However, several components (such as a stator and statorcoils) are removed for purposes of illustration. In this regard, theelongated portion 830 may be fitted with a connector (not shown) thatterminates one or more electrical connections of the printed circuitassembly 828 such that the connector may electrically couple withanother component. Further, the elongated portion 830 may extend throughan opening (such as the opening 506 shown in FIG. 10) and the printedcircuit assembly 828 may be disposed on a pillow (such as the pillow 512shown in FIG. 10).

In some embodiments, the printed circuit assembly 828 is a flexibleprinted circuit assembly. As shown, the printed circuit assembly 828includes a first post 842, a second post 844, and a third post 846.While the embodiment of the printed circuit assembly 828 shows threeposts, any number of posts necessary to connect stator coil wires in adesired manner may be used. For example, a 3-phase DC motor may requirethree posts, as shown. However, other motors may include more or lessposts. Also, the printed circuit assembly 828 also includes extension inlocations proximate to the posts. For example, the printed circuitassembly 828 includes a first extension 852 proximate to first post 842.In this manner, the first post 842, which includes electricallyconductive portions, does not contact any surface below the printedcircuit assembly 828 (for example, a pillow) thereby preventing, or atleast reducing, the probability of an electrical short. Also, as shownthe printed circuit assembly includes a second extension 854 and a thirdextension 856 to accommodate the second post 844 and the third post 846,respectively.

Also, in some embodiments, the printed circuit assembly 828 is a ring,annulus, or other shape designed to accommodate various components of afan assembly. In the embodiment shown in FIG. 15, the printed circuitassembly 828 is a U-shaped arc that includes a first edge 864 and asecond edge 866. The first edge 864 and/or the second edge 866 may beshaped to conform to other structures positioned on, or proximate to, apillow (or other substrate). For example, as shown FIG. 15, the firstedge 864 and the second edge 866 combine to generally define a V-shapedconfiguration, which may assist in aligning the printed circuit assembly828, and in turn, with a component having corresponding shape.

The bushing may include additional features designed to facilitateconnection of wires of a stator coil during an assembly operation of afan assembly. For example, FIG. 16 illustrates an isometric view of anembodiment of a stator 914 surrounding a bushing 916, in accordance withthe described embodiments. In some embodiments, the bushing 916 isformed from a non-electrically conductive material (or materials)capable of withstanding heat in order to facilitate certain operations,such as soldering. The bushing 916 may include several protrudingfeatures having pins formed from an electrically conductive material (ormaterials), with the pins designed to receive a wire from a wire portionof the stator coils. For example, as shown in FIG. 16, the bushing 916includes a first protruding feature 942 integrally formed with thebushing 916. In other words, the bushing 916 and the first protrudingfeature 942 are formed as a single, continuous body from the samematerial or materials. This may be performed by, for example, aninjection molding or a compression molding operation having a moldcavity with a size and a shape of the bushing 916 and one or moreprotruding features. Accordingly, the first protruding feature 942 isformed from a non-electrically conductive material (or materials). Asshown, the first protruding feature 942 includes a first pin 952designed to receive a wire portion 922 from the first stator coil 918.In some embodiments, the bushing 916 is formed from a relatively lessrigid material such that the first protruding feature 942 is flexiblewith respect to the stator 914. Also, the first stator coil 918, thefirst protruding feature 942, and the first pin 952 may berepresentative of the remaining stator coils, protruding features, andpins, respectively.

In some embodiments, the first pin 952 is an electrically conductivefeature that extends beyond the first protruding feature 942, allowingthe wire portion 922 to be electrically connect with, for example, asolder material. In the embodiment shown in FIG. 16, the first pin 952is a pogo-pin having spring-loaded pins designed to receive the wireportion 922. Also, the first pin 952 extends from a top portion of thefirst protruding feature 942 and further extending from a bottom portion(not shown) of the first protruding feature 942. In this manner, thefirst pin 952 may electrically connect the first stator coil 918 with aprinted circuit assembly (not shown). Also, the first pin 952 may beelectrically connected to another component at the bottom portion(discussed below). Similar to the posts shown in FIG. 15, the protrudingfeatures shown in FIG. 16 are positioned between at least some of thestator coils.

FIGS. 17 and 18 illustrate top and bottom views, respectively, of thestator 914 and bushing 916, both of which are shown in FIG. 16. However,the stator coils in FIG. 16 are removed for purposes of illustration andclarity. FIG. 16 illustrates the bushing 916 having a first protrudingfeature 942, a second protruding feature 944, and third protrudingfeature 946, each of which are centered between adjacent stator poles.The stator coils wound around the stator poles are removed for purposesof clarity and illustration. Also, the first pin 952 of the firstprotruding feature 942 is designed to be elevated with respect to thestator coils (not shown) in order to facilitate a wire connectionoperation between the first pin 952 and a wire portion of a stator coil.It will be appreciated that the first pin 952 is representative of theremaining pins. Also, protruding features of the bushing 916 may includeone or more channel features that provide functional enhancementssimilar to those of the channel 428 (shown in FIG. 8). For example, asshown in FIG. 17, the second protruding feature 944 includes a channel948. The channel 948 may be designed to receive a flange feature (notshown) as well as an adhesive to adhesively secure the bushing 916 withthe flange feature. Also, the channel 948 may be designed to form a gapregion with graduated gap distances in a manner previously described.

FIG. 18 illustrates a bottom view of the bushing 916, showing the pinsof the protruding features having an arch-shaped, cantilevered bend. Thecantilevered bend as well as the flexibility of the protruding featuresact as a spring to create the “pogo action” of the pogo pin, in thoseembodiments in which the pins are pogo pins. For example, the first pin952 is designed to provide a preloading force to ensure electricalcontact to a pad (not shown) on a surface or region of another component(for example, a circuit board or a connector of the keyboard 212 shownin FIG. 3) adjacent to the fan of an electronic device 200 (shown inFIG. 3). The pins may also include a connector integrated with thebushing 916. For example, the first protruding feature 942 includes afirst connector 954 formed with the bushing 916. The first connector 954is designed to receive the first pin 952, and may be representative ofthe remaining connectors shown in FIG. 18. Also, the pins extending fromthe bottom portion of bushing 916 indicate a location in which the pinsmay exit a pillow of a fan assembly in order to make an electricalconnection with a contact pad (or pads) located externally with respectto the fan assembly. This allows the stator coils having wires connectedwith the pins to be electrically connected to another component orcomponents, such as a motor control circuit 319 (shown in FIG. 3). Also,in this manner, the stator coils need not be electrically connected to acomponent via a printed circuit assembly (such as the printed circuitassembly 828, shown in FIG. 16). Further, the bushing 916 may be formedfrom a non-electrically conductive material (or materials). In thismanner, the protruding features may form electrically insulatingfeatures for at least a portion of their respective pins.

To further illustrate, FIG. 19 illustrates a bottom view of pillow 912(or base) engaged with the bushing 916, with the pillow 912 havingopenings allowing the pins of a bushing 916 to extend through the pillow912 in order to electrically connect the stator coils (not shown) with acomponent, such as a contact pad or another printed circuit assembly. Asshown, the first pin 952 (disposed in the first protruding feature 942,shown in FIG. 18) extends through a first opening 964 of the pillow 912.When the bushing 916 and the protruding feature are formed fromnon-electrically conductive materials, the bushing 916 and theprotruding feature define an insulating sleeve around the first pin 952to avoid electrical shorting to the pillow 912 when an electricalcurrent flows through the first pin 952. It will be appreciated that thefirst pin 952 and its features are representative of the remaining pins.

Although several means or locations for wire terminations are disclosed,other means may be available. For example, in some embodiments,individual male or female connectors are located between the statorcoils, and the electrical connection of the fan assembly can be madethrough terminals of these connectors.

FIG. 20 illustrates a flowchart 1000 showing method for reducing adimension of a motor of a fan assembly of an electronic device. In step1002, several coils of the fan assembly are positioned within a recessedportion of a pillow. In some embodiments, the coils are stator coils ofthe fan assembly. In some embodiments, the coils include a first statorcoil and a second stator coil, with first stator coil having a wireportion capable of electrically connecting with a circuit assembly in alocation between the first stator coil and the second stator coil. Forexample, a bushing may include several protruding features, each ofwhich may include a pin or other feature. Alternatively, a circuitassembly may include several protrusions, each of which is designed toreceive a wire portion of the first stator coil and/or the second statorcoil.

In step 1004, the wire is terminated on a protrusion positioned betweenthe first stator coil and the second stator coil. In some embodiments,the first stator coil is electrically connected to a motor controlcircuit via the protrusion and a printed circuit. In some embodiments,the protrusion is centered between adjacent stator coils. In someembodiments, the protrusion is electrically conductive. In otherembodiments, the protrusion is an assembly including a non-electricallyconductive portion (e.g., nonconductive sleeve positioned on outersurface of the protrusion) that is part of a non-electrically conductivestator bushing and an electrically connecting portion. In thisembodiment, the protrusion (or protrusions) may include a pin configuredto receive and terminate the wire of the stator coil.

The various aspects, embodiments, implementations or features of thedescribed embodiments can be used separately or in any combination.Various aspects of the described embodiments can be implemented bysoftware, hardware or a combination of hardware and software. Thedescribed embodiments can also be embodied as computer readable code ona computer readable medium for controlling manufacturing operations oras computer readable code on a computer readable medium for controllinga manufacturing line. The computer readable medium is any data storagedevice that can store data which can thereafter be read by a computersystem. Examples of the computer readable medium include read-onlymemory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, andoptical data storage devices. The computer readable medium can also bedistributed over network-coupled computer systems so that the computerreadable code is stored and executed in a distributed fashion.

The foregoing description, for purposes of explanation, used specificnomenclature to provide a thorough understanding of the describedembodiments. However, it will be apparent to one skilled in the art thatthe specific details are not required in order to practice the describedembodiments. Thus, the foregoing descriptions of the specificembodiments described herein are presented for purposes of illustrationand description. They are not targeted to be exhaustive or to limit theembodiments to the precise forms disclosed. It will be apparent to oneof ordinary skill in the art that many modifications and variations arepossible in view of the above teachings.

What is claimed is:
 1. A fan assembly suitable for use in a computingsystem, the fan assembly comprising: a stator including a first statorpole and a second stator pole; a coil wound around the first stator poleand the second stator pole to define a first stator coil and a secondstator coil, the coil including a wire portion; and a circuit assemblyincluding a post positioned between the first stator coil and the secondstator coil, the post having an electrically conductive region thatreceives the wire portion to electrically connect the first stator coilwith the circuit assembly.
 2. The fan assembly of claim 1, furthercomprising a pillow having a recessed portion that receives a portion ofthe first stator coil.
 3. The fan assembly of claim 2, wherein thepillow further comprises an opening extending through the pillow, andwherein the circuit assembly extends through the opening to electricallycouple with a component.
 4. The fan assembly of claim 2, wherein thecircuit assembly comprises an extension that receives the post.
 5. Thefan assembly of claim 4, wherein the post is fixedly coupled with thecircuit assembly.
 6. The fan assembly of claim 5, wherein the post issoldered to the circuit assembly along a surface of the circuitassembly.
 7. The fan assembly of claim 1, wherein the post ischaracterized by an exterior region comprising an insulating material.8. The fan assembly of claim 1, wherein the post comprises copper orbrass.
 9. A computing system fan assembly comprising: a stator pole; acoil coupled about the stator pole; a circuit board; a post extendingnormal to the circuit board adjacent the coil; and a conductiveextension coupled between the coil and the post, wherein the conductiveextension electrically couples the coil with the circuit board, andwherein the conductive extension is coupled with a surface of the post.10. The computing system fan assembly of claim 9, wherein the post ischaracterized by a cylindrical shape having a top surface and a bottomsurface, and wherein the conductive extension is coupled with the postacross the top surface.
 11. The computing system fan assembly of claim10, wherein the post is coupled with the circuit board proximate thebottom surface.
 12. The computing system fan assembly of claim 9,wherein the circuit board comprises a first surface along which the postis coupled with solder or a conductive adhesive.
 13. The computingsystem fan assembly of claim 9, wherein the post is characterized by anexterior region comprising an insulating material.
 14. The computingsystem fan assembly of claim 9, further comprising a pillow defining arecessed portion within which the coil extends.
 15. A fan assemblysuitable for use in a computing system, the fan assembly comprising: astator including a first stator pole and a second stator pole; a firststator coil extending about the first stator pole; a second stator coilextending about the second stator pole; a wire extending from one of thefirst stator pole or the second stator pole; and a circuit assembly; anda post extending normal to the circuit assembly between the first statorcoil and the second stator coil, wherein the post comprises anelectrically conductive region to which the wire is coupled.
 16. The fanassembly suitable for use in a computing system of claim 15, wherein thepost couples with the circuit assembly proximate a first surface of thepost.
 17. The fan assembly suitable for use in a computing system ofclaim 16, wherein the post is soldered with the circuit assembly at anintersection of the post and the circuit assembly.
 18. The fan assemblysuitable for use in a computing system of claim 16, wherein the wireextends to and couples along second surface of the post opposite thefirst surface.
 19. The fan assembly suitable for use in a computingsystem of claim 15, further comprising a pillow defining an aperturethrough which the circuit assembly extends.
 20. The fan assemblysuitable for use in a computing system of claim 15, wherein the circuitassembly comprises an arcuate extension along which the post is coupled.